CHAPTER - 9

DISCUSSION OF RESULTS AND CONCLUSIONS

9.1 INTRODUCTION:
The exploration and alleviation of soft condition is very essential for effective, useful and
prolonged performance of any machines which are installed using threaded fasteners.
The issue of soft foot condition is very significant where machine downtime due to
failure or repair is crucial, e.g. machines involved in mass or continuous type of
production system. In this context, areas of application of minimization of effects of soft
foot condition are: Electric Motors, Pumps, Engines, Compressors, Machine Tools,
Turbines, Electric Generators, Large Gear Boxes, Large Fans and Blowers,
Rolling/Pulverizing Mills etc. The list is endless, as the soft foot condition may be
present wherever the two members that are not perfectly flat with each other and
joined by threaded fasteners. As such, in this research work, the analytical and
experimental studies on dynamic loosening of threaded fasteners in machine structures
with special reference to soft foot condition have been carried out to investigate the
effect of joint parameters on the performance of bolted joint subjected to vibration.
Chapter 1 deals with significance of assessment of soft foot condition, need of soft foot
condition alleviation and its application in the different areas, brief historical resume of
dynamic loosening of bolted joint with special reference to soft-foot condition etc. A
detailed literature review of the research work in the area of dynamic loosening of
threaded fasteners with special reference to soft foot condition has been presented in
Chapter 2. From the literature review it is observed that many factors (more than 70
and soft foot is one of them) either directly or indirectly responsible for bolted joint
integrity. These factors are more in numbers and could not define the interrelation
between each other because of their overlapping and complex nature. In Chapter 3 the
‘Interpretive Structural Modeling (ISM)’ approach is used to develop a model which will
logically identify the relation between these factors and also estimate the level of
significance of each of one of them. Chapter 4 deals with the analysis of effects of design
parameters such as diameter, pitch, grip length and friction etc. on bolted connection to
understand the preload generation process. A ‘Quality Function Deployment (QFD)’
approach is used to compare four commonly used joining techniques on the basis of
different customer requirements and engineering characteristics using House of Quality

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(HoQ) concept. Sensitivity Analysis is also carried out for knowing the criticality of these
factors. A novel technique named ‘Desirability Optimization Methodology (DOM)’ is
described to select the best suitable combination of bolt size and grade based on the
price criterion. ‘Taguchi Method’ and ‘Response Surface Methodology (RSM)’ are
discussed for optimization of various design parameters to achieve maximum bolt
preload so that the joint can sustain the vibratory environment. In Chapter 5 Reliability
Analysis of bolted joint subjected to vibration has been carried out and reliability values
of individual factor and system reliability have been calculated to understand the
significance and criticality of each factor. Chapter 6 discusses the issue of soft foot
condition in detail and how it influences the performance of bolted joint with the help of
‘Tent Diagram’. Finite Element Analysis (FEA) has been carried out to verify the effect of
soft foot condition on bolt preload and clamping force in the joint. In Chapter 7 the
‘Analytic Hierarchic Process (AHP)’ is used to finalize the bolted joint parameters for
experimental investigations based on the rank and priority. Initially the dimensional
and material conformance of the threaded fasteners of different sizes and grades are
tested and checked in accredited laboratories. An experimental setup developed for
measurement of the bolt preload by torque control, stretch control and angle control
method simultaneously is used to perform clamp load relaxation analysis for different
bolt sizes and grades received from different manufacturers. The generation of bolt
preload under soft foot condition is assessed by using Taguchi Method to derive the
optimum level of the parameters under consideration. The vibration analysis of a
machine at various mass and support positions are carried out in Chapter 8 to see the
effect of soft foot condition on vibration response amplitude. The variation of power
consumption is also measured during these experiments. A combined approach of
‘Design of Experiments (DOE)’ and ‘Dimensional Analysis (DA)’ is used to develop the
mathematical models for Residual Preload (FR) and Loosening Torque (TL).

9.2 DISCUSSION OF RESULTS OF ISM AND FMEA ANALYSIS OF BOLTED JOINT:

Interpretive structural modeling (ISM) which is a qualitative tool used to comprehend
and simplify the complex interrelationships between the soft foot condition and its
effect on bolted joint integrity through methodical, systematic, and logical approach.
The developed ISM model partitioned the 39 identified factors (categorized into four
groups) into five levels of hierarchical significance. The MICMAC Analysis of ISM model
is used to analyze the driving power and the dependence of the variables. The derived
variables are classified into four clusters (refer Figure 3.3 on page 45). The first cluster

206
consists of the autonomous variables that have weak driving power and dependence.
Second cluster consists of the dependent variables that have weak driving power but
strong dependence on other variables. Third cluster has the linkage variables that have
strong driving power and also strong dependence. Fourth cluster includes the
independent variables having strong driving power but weak dependence. From the
MICMAC analysis it has been observed that the factor 31 (Vibration Loosening) and
36 (Additional stresses (bending) in the bolt) falls in cluster 3, which needs special
attention. It is observed that the vibration is the major threat to bolted joint integrity
and soft foot condition will accelerate the adverse effect on the same.
The severity diagram (refer Figure 3.4) drawn using RPN data shows that; (i) Frame
distortion, Mechanical impedance, Additional stresses (Bending) in the bolt, Rotor-
stator eccentricity and Rise in temperature i.e. factors 33, 35, 36, 38 and 39 respectively
belong to medium risk region. (ii) Whereas the Vibration loosening, Shaft
misalignment/Unbalance, Thermal stripping and Cocked bearing i.e. factors 31, 32, 34
and 37 respectively indicating high risk. The factors highlighting high risk for the bolt
joint integrity are the ill effects of the soft foot condition. The region of severity diagram
in which these factors are lying are also indicated as area which creates warranty issues,
which clearly states that there is a great need of paying the attention towards these
factors so that the bolted joint integrity will be maintained throughout the useful life of
any machine or structure. The findings from the FMEA of the soft foot condition also
validate the ISM model showing the interelation between the 39 factors with integrated
total objective of maintening bolted joint integrity under soft foot condition.
This finding is also strongly supported by FMEA.

9.3 DISCUSSION OF RESULTS OF EFFECTS OF DESIGN PARAMETERS ON BOLTED

CONNECTION:
Quality Function Deployment (QFD) is a planning and problem solving tool that is
finding growing acceptance for translating customer requirements into the engineering
characteristics of a product or process. From the HoQ of QFD analysis following are the
observations about Bolted joint compared with other three types of joining techniques
e.g. Adhesive joint, Riveted Joint and Welded Joint.
Based on Customer requirements
Welded joint gives higher strength than bolted joint but lacks on flexibility. Bolted joint
can connect similar or dissimilar material easily with less time to joint preparation
compared to adhesive and welded joint. Bolted joint exhibits poor performance on the

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criterion of weight to strength ratio, vibration resistant, leak proof, assembly cost and
parent material destruction, over the other three types of joints.
Based on engineering characteristics
Bolted joint is good at less assembly time, reusability and corrosion resistant over the
other three types of joint. Whereas it gets low rank in requirements of surface
preparation, component shape to be assembled, material to be removed from joint, need
of proper joint design, vibration resistance and creation of burrs or splinter during joint
preparation. The engineering characteristics of the joint such as, Surface preparation,
Corrosion and Burrs or Splinter are pointing towards the possibility of development of
soft foot condition. These process characteristics have to be kept under control to
minimize the effect of soft foot condition.
Sensitivity Analysis : The general torque-tension relationship given in equation 4.2 is
used to determine the relative sensitivities for more meaningful understanding of the
significance of parameters. From the sensitivity analysis carried out the most important
or sensitive parameter found is preload (Fi) produced by tightening torque (T) and the
tightening torque (T) mainly depends upon thread friction and bearing friction.
Effect of Nominal Diameter Parameter : For bolt size M4 to M39 there is a decreasing
trend of percentage loss of preload, whereas percentage loss of preload again starts at
M42 bolt size, this is may be due to provision of large pitch values to minimize the effect
of friction during torqueing. Bolt nominal diameter plays an important role in the
strength consideration of the threaded fastener, for a given joint. More number of
slender (small diameter) bolts are preferred, instead of a small number of large size
bolts. Desirability Optimization Methodology (DOM) gives the choice or option to
select best suitable bolt size and grade based on the cost criterion. For e.g. one can select
M6 12.9 or M10 8.8 having equal desirability (refer Table 4.21). Similarly one can
choose the option based on his or her judgment. The proper selection of bolt diameter
and grip length (d/L = aspect ratio) is desired to achieve the required preload.
It is seen that large pitch values help to achieve more clamping force due to lesser
frictional resistance. However, the larger the pitch value, smaller is the effective tensile
stress area. In general, both coarse and fine threads are capable of providing sufficient
strength for most applications.
The ‘Response Surface Methodology (RSM)’ and ‘Taguchi Method’ discussed proposes
the methodology for maximizing the bolt preload by suggesting the tightening process
parameters which can surpass the uncertain effect of friction.

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9.4 DISCUSSION OF RESULTS OF RELIABILITY ANALYSIS OF BOLTED JOINT SUBJECTED
TO VIBRATION:
For any bolted connection, the most important criterion for its effectiveness is the joint
integrity. Under severe operating conditions such as presence of vibration, soft foot
condition etc., bolted connection must maintain its joint strength. Since the reliability of
a joint against vibration is the key issue for the designer. From the Taguchi and
reliability analysis of the vibration induced bolt loosening of a typical bolted joint, it
is observed ; (1) A2 B2 C2 D2 E2 F2 G2 H2 I1 J2 K1 i.e. Bolt size = ¾“, Thread lubrication =
MoS2, Hole tolerance = Tight, Bolt preload = 0.8 Sy, Locking device = Self-locking, Grip
length = 2”, Thread pitch = Fine, Plate lubrication = MoS2, Class of fit = 2, Joint
configuration = Concentric, Mass of configuration = Mass of specimen under Axial 40g
vibration exhibits better bolt loosening resistance to vibration. (2) From Pareto
ANOVA analysis; Mass of configuration (K), Joint configuration (J), locking device (E)
and Grip length (F) give maximum contribution, whereas Thread lubricant (B), Plate
lubrication (H), Thread pitch (G) give moderate or average contribution and Bolt size
(A), Hole size (C), Bolt preload (D) and class of fit (I) is insignificant. (3) From the full
factorial simulation (i.e. 211 = 2048) analysis of all the cases, Ax 40g case shows 316
possibilities of no loosening condition. (4) Individual element reliability calculations
correlate the results obtained by Taguchi analysis. (5) System reliability data for each
case (i.e. poor and good factor-level combination) correlate the Taguchi analysis and
its results. The maximum system reliability is obtained for A 2 B2 C2 D2 E2 F2 G2
H2 I1 J2 K1 i.e. 0.999889.
From the reliability analysis it is observed that the transverse vibration is having severe
effect on the joint integrity and the bolted joint is susceptible to loosening under such
circumstances.

9.5 DISCUSSION OF RESULTS OF BOLTED JOINT ANALYSIS WITH SPECIAL REFERENCE

TO SOFT FOOT CONDITION:
Soft foot is a term used to describe conditions that manifest themselves as machine
frame distortion. This non-uniformity causes stress on the machinery when the foot is
forced into place by tightening the hold-down bolt. The development of bolt preload is
affected due to soft foot condition during the tightening process is explained with the
help of ‘Tent Diagram’. From the ‘Tent Diagram’ it is seen that the certain amount of
tightening torque is utilized to create bending stresses in the bolt instead of tensile
stresses due to soft foot condition. Finite Element Analysis further elaborates this

209
discussion and shows the uneven stress distributions in the bolt as well as joint
members. Higher stress concentration and deformations observed in the bolt and joint
members of the bolted joint subjected to soft foot condition. From the plot of stress vs.
plate thickness, the maximum stress value found is approximately 373 Mpa for bolted
joint with soft foot condition and 354 Mpa for without soft foot case (refer Figure 6.11).
Whereas along the bolt diameter the highest stress value observed is 756 Mpa for bolted
joint with soft foot condition and 577 Mpa for without soft foot case (refer Figure 6.13).
The values of stresses present in the clamped plate and bolt are 5 percent and 24
percent respectively more in soft foot condition. Effectively dealing with soft foot is
beneficial in time and money saved when compared with more costly repairs.

9.6 DISCUSSION OF RESULTS OF EXPERIMENTAL INVESTIGATIONS: STATIC AND

DYNAMIC ANALYSIS:
The priority and significance of bolted connection parameters are decided by using
Analytic Hierarchic Process (AHP), which helps to choose the important parameters for
conducting the experiments. The theoretical analysis carried out in section 4.4.4 clearly
shows that there is a possibility of initial preload loss upto 3.5 percent due to variations
in the fastener dimensions. The dimensional measurements carried out confirm the
variations in the thread dimensions over the standard dimensions mentioned in the
standard handbook. Also upto 5 percent variation in the preload development have
been observed in similar size and grade bolts. Due to these dimensional variations there
is a further possibility of not getting the desired fit between the nut and bolt. The initial
preload relaxation upto 7 percent in the different bolt sizes and grades are observed
during the first hour after the bolt tightening. Both the generation of insufficient preload
and loss of preload due to initial relaxation may increase the possibility of bolt loosening
under dynamic conditions.
The testing of bolts of different size and grade carried out on the basis of material
strength and property satisfy the strength and property criterion as per the standards.
Results obtained from the bolt material testing can be used to select appropriate bolt
size using Desirability Optimization Methodology (DOM) discussed in section 4.4.4.
The experiments carried out to assess the effect of soft foot condition on the generation
of bolt preload using Taguchi method identified the optimized parameters for higher
preload, clearly show the relevance of research work carried out earlier. The smaller
bolt size with larger grip length (also increased by addition of washer) and reduction in

210
friction (due to lubrication and retightening of bolts) are key design and process
parameters help to achieve the higher bolt preload.
From the machine vibration analysis under soft foot condition, it is observed that the
level of vibration is significantly increased than the machine operating under without
soft foot condition. The level of vibration increased due to soft foot condition
irrespective of mass and support positions described by 18 sets. The power
consumption of the machine also increased due to soft foot condition. The mathematical
models developed for Residual Preload (FR) and Loosening Torque (TL) using
Buckingham Pi theorem shows good correlation between the experimental and
calculated values (with R2 values 89.39 and 88.87 respectively). The residual preload
factor (a non-dimensional response variable) is created to assess the performance of
various joint factors towards maintaining the joint integrity against vibration. Smaller
the value of the residual preload factor betters the immunity of the bolted joint against
vibration.

9.7 CONCLUSIONS:
1. From the QFD analysis, the bolted joint appears to be the best suitable option for
joining members together than the welded, riveted and adhesive joining
techniques from the customer requirements and engineering characteristics
point of view.
2. From the critical review of literature and discussions with the experts from the
industry and academics, sixty nine (69) factors (as given in Table 3.1) have been
identified which are either directly or indirectly enhance or deteriorate the
bolted joint integrity under soft foot condition. The developed ISM model
partitioned the 39 identified factors (obtained from 69 factors as given in Table
3.1), categorized into four groups and into five levels of hierarchical significance.
From the MICMAC analysis it is observed that the vibration is the major threat to
bolted joint integrity and soft foot condition. The findings from the FMEA of the
soft foot condition also validate the ISM model showing the interelation between
the 39 factors with integrated total objective of maintaining bolted joint integrity
under soft foot condition.
3. It has been shown that the most important sensitive parameter in Torque-
Tension relationship is the preload produced by tightening torque which is
affected by thread friction and bearing friction.

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4. The reliability analysis of the bolted joint element and the system has been
carried out, from which it is concluded that the transverse vibration is having
severe effect on the joint integrity and the bolted joint is susceptible to loosening
under severe operating conditions such as presence of vibration and soft foot
condition (as per the results of MICMAC analysis).
5. A methodology for maximizing the bolt preload has been proposed in which the
tightening process parameters can be obtained using the methods of Response
Surface Methodology (RSM) and Taguchi.
6. From the results of Finite Element Analysis of the bolted joint under soft foot
condition it can be concluded that there exists an uneven stress distribution
(stress concentration) and higher deformations in the bolt as well as joint
members which may accelerate the bolted joint failure and may lead to costly
maintenance (repairs) and therefore in order to save time and money spent on
maintenance (repairs), it is important to carefully design the bolted joint system
under soft foot condition.
7. From the results of experiments carried out to assess the effect of soft foot
condition of bolt preload using Taguchi method, it can be concluded that the
smaller bolt size with larger grip length (also increased by addition of washer)
and reduction in friction (due to lubrication and retightening of bolts) are key
design and process parameters to achieve the higher bolt preload.
8. From the results of AHP it is possible to select the important parameters for the
design of a bolted joint under soft foot condition. Also this method is helpful to
choose the significant parameters for conducting the experiments on
measurement of clamping force, preload relaxation of the bolted joint.
9. From the machine vibration analysis under soft foot condition, it can be
concluded that the level of vibration response goes on increasing with the
increase in the speed of the machine irrespective of support locations and mass
positions. A relation between vibration response amplitude and speed of the
machine can be developed by using fitted line regression analysis. From this
equation it is possible to predict amplitude of response of the given machine,
under given type of soft foot condition, for the desired value of the speed of the
machine.
10. The relationships for Residual Preload (FR) and Loosening Torque (TL) with bolt
diameter, bolt material strength, grip length, gap between two joining members,

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 tightening torque and vibration amplitude, using Buckingham Pi theorem, have
been developed which can be used to determine the bolted joint parameters
such that the loosening possibility of the bolted joint under soft foot condition is
minimized. The high ‘R2 value’ obtained for the developed models indicates that
the developed equations are reliable.
11. The results of analytical and experimental studies carried out on dynamic
loosening of threaded fasteners in machine structures with special reference to
soft foot condition will be useful as guidelines for design of a bolted joint for
improved joint integrity under soft foot condition.

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 CONTRIBUTIONS OF THE RESEARCH WORK

The results of research work carried out will be useful as guidelines for design of a
bolted joint for improved joint integrity under soft foot condition.
From the customer requirements and engineering characteristics point of view, the
bolted joint has been shown as the best suitable option for joining members together
than the welded, riveted and adhesive joining techniques.
It has been shown that the ‘Interpretive Structural Modeling (ISM)’ approach can be
effectively used to develop a model which will logically identify the relation between
various factors influencing bolted joint integrity under soft foot condition and also
estimate the level of significance of each of these factors. The procedure for the selection
of the important parameters for the design of a bolted joint under soft foot condition has
been presented using the Analytic Hierarchic Process (AHP).
For a Torque-Tension relationship, a sensitivity analysis method has been proposed to
determine the most significant parameter responsible for maintaining bolted joint
integrity under soft foot condition. The Desirability Optimization Methodology (DOM)
has been effectively used for selection of appropriate bolt size and bolt grade for a
bolted joint based on cost criterion. To design a bolted joint to prevent its dynamic
loosening, the effective use of ‘Reliability Analysis’ approach has been demonstrated.
It has been shown that the Finite Element Analysis can be effectively used to determine
stress distribution (stress concentration) and deformations of a bolted joint under soft
foot condition. A procedure has been suggested using Taguchi approach for bolt preload
optimization and minimization of early stage preload relaxation when the bolted joint of
the machine is with soft foot condition.
A relation between vibration response amplitude and speed of the machine has been
developed by using fitted line regression analysis to predict amplitude of response of
the given machine, under given type of soft foot condition, for the desired value of the
speed of the machine. A combined approach of Design of Experiments (DoE) and
Dimensional Analysis (DA) has been developed to establish the relationships for
Residual Preload (FR) and Loosening Torque (TL) with bolt diameter, bolt material
strength, grip length, gap between two joining members, tightening torque and
vibration amplitude. These relationships will be helpful to determine the bolted joint
parameters such that the loosening possibility of the bolted joint under soft foot
condition is minimized to improve the joint integrity.

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 SCOPE FOR THE FUTURE WORK

The scope for future research work in this area is as follows;

The focus of the present study was on the analytical and experimental studies on the
joint integrity of a bolted joint under soft foot condition wherein the tension in the bolt
created by the tightening torque was limited upto or near to the elastic limit of the bolt
material. However to augment the preload capacity of the bolted joint the tension in the
bolt induced by the tightening torque can be extended beyond the yield point (i.e. in the
plastic region) and the further studies can be carried out in this area.

The present study of dynamic loosening of bolted joint under soft foot condition is
carried out for parallel soft foot condition using metal shims. However it can be
extended to the angled soft foot condition and a variety of types of materials and shapes
of shims.

The analytical and experimental studies can be carried out

(i) in the area of fatigue analysis of a bolted joint under soft foot condition to ensure the
reliability of the joint and
(ii) in the area of diagnostic maintenance of the bolted joint under soft foot condition.

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 PUBLICATIONS RELATED TO RESEARCH WORK

INTERNATIONAL JOURNAL
(1) Satish S. Kadam and S. G. Joshi, April 2013, “Nominal Diameter, Clamp Length and
Thread Pitch Analysis for Bolt Preload Augmentation”, International Journal of
Mechanical Engineering and Technology, Vol. 4 Issue 2 pp. 141-151.
Percentage of citation: 74.5%
ISSN Print: 0976 6340, ISSN Online: 0976 6359
Impact Factor: 5.7731 Calculated by GISI (jifactor.com)

(2) Satish S. Kadam and S. G. Joshi, 2012, “Interpretive Structural Modeling (ISM) of
Bolted Joint Subjected to Dynamic Loosening Under Soft Foot Condition” Applied
Mechanics and Materials, Trans Tech Publications, Switzerland, Vol. 110-116, pp. 3047-
3053.
doi: 10.4028/www.scientific.net/AMM.110-116.3047
ISSN: 1022-6680
Impact Factor: 2.87

(3) Satish S. Kadam and S. G. Joshi, September 2011, “Bolt Preload Analysis Under Soft
Foot Condition Using Taguchi Method”, Journal of Technology World, Malaysia
Volume III, Issue 3, pp.137-144
ISSN : 2180-1614
Impact Factor : 1.78

NATIONAL JOURNAL
(4) Satish S. Kadam and S. G. Joshi, November 2007, “ Vibration Induced Loosening of
Dimensionally Non-Conforming Bolted Joints”, Bharati Vidyapeeth University Research
Journal, Volume V, Number 2, pp.47-52

216
INTERNATIONAL CONFERENCE
(5) Satish S. Kadam and S. G. Joshi, 26th – 28th November 2010, “Interpretive Structural
Modeling (ISM) of Bolted Joint Subjected to Dynamic Loosening Under Soft Foot
Condition”, International Conference on Mechanical and Aerospace Engineering,
ICAMAE-2010, Kuala Lampur, Malaysia,
IEEE Catalog Number: CFP1047L-PRT
ISBN: 978-1-4244-8772-1
This paper has been sent to the ‘Applied Mechanics and Materials’ Journal by the
organizer of the conference

(6) Satish S. Kadam and S. G. Joshi, 4th – 6th January 2010, “Vibration Induced Bolt
Loosening Analysis Using Taguchi and Reliability Approach”, 3rd International
Conference on Advances in Mechanical Engineering, ICAME-2010, Sardar Vallabhai Patel
National Institute of Technology (S.V.N.I.T.), Surat , Gujrat

(7) Satish S. Kadam and S. G. Joshi, 19th – 21st March 2009, “Analysis of Bolt Tightening
Process Using Taguchi Method”, Emerging Research and Advances in Mechanical
Engineering, ERA-2009, Velammal College of Engineering, Chennai, (Tamilnadu)
ISBN-13 978-81-908086-1-3 (Proceedings published by McMillan)

(8) Satish S. Kadam and S. G. Joshi, 30th January-2nd February 2007, “Tightening Torque
Optimization Using Response Surface Methodology (RSM)”, 8th International Conference
on Vibration Problems, ICOVP-2007, Bengal Engineering and Science University,
Kolkata (Howrah) 711 103
ISBN: 978-1-4020-9091-2 (Proceedings published by Springer)
e-ISBN: 978-1-4020-9100-1

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